Remove/install left cylinder head

AR01.30-D-5770TSV

Remove/install left cylinder head

18.02.2020

Engine

642 in model 907

1

Heat shield

2

Bolts

3

Bracket

4

Screw

5

Fuel lines

10

Cylinder head

12

Seal

13

Cylinder head bolt

14

Cylinder head bolt

15

Crankcase

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove charge-air distributor.

AR09.41-D-8683TSV

2

Remove oil filter housing.

AR18.20-D-3471TSV

3

Remove fuel high-pressure pump.

AR07.02-D-1028TSV

4

Remove valve clearance compensating elements.

AR05.00-D-2016TSV

5

Remove heat shield (1).

 To do this, remove screws (2).

6

Remove the bracket (3).

 To do this, remove bolt (4).

7

Place fuel lines (5) outside the working area.

8

Remove slide rail pins at cylinder head (10).

AR01.30-D-5800-04TSV

 Threaded bolt

*116589013400

 Impact extractor

*116589203300

 Puller

*605589003300

9

For a cooled down engine, release cylinder head bolts (13, 14) in stages in reverse order to tightening procedure and remove.

AR01.30-D-5800-01TSV

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Installation:
Observe tightening procedure and tightening specifications for cylinder head bolts (13, 14).
Distortion of cylinder head (10) can otherwise occur.

 Installation: Slightly oil thread and bolt head contact surfaces of cylinder head bolts (13, 14).

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1001-01TSV

10

Remove cylinder head (10) and seal (12).

 Installation: Install new seal (12).

11

Remove exhaust manifold from cylinder head (10).

If cylinder head (10) is replaced.

AR14.10-D-3007TSV



Clean

12

Clean threaded holes of cylinder head bolts (13, 14) in crankcase (15).


Cover cylinder bores and contact surface at crankcase (15).
Engine damage can occur otherwise.

 Blow out dirt and fluids from threaded holes.

13

Clean sealing surfaces at crankcase (15).

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

14

Clean sealing surfaces at cylinder head (10).

If cylinder head (10) is reused.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A



Check

15

Check stud bolts of exhaust manifold at cylinder head (10).

Depending on the findings,



Replace damaged stud bolts.

 Stud bolt, exhaust manifold to cylinder head

*BA14.10-N-1002-02TSV

16

Check cylinder head bolts (13).

AR01.30-D-5800-03TS

Cylinder head bolt

*BE01.30-N-1001-04A

Depending on the findings,



Replace affected cylinder head bolts (13).

17

Check cylinder head (10) and crankcase (15) for damage.

 Rework of sealing surfaces at cylinder head (10) and/or at crankcase (15) is not permitted.

Depending on the findings,



Replace cylinder head (10) and/or crankcase (15).

18

Install in the reverse order.



Check

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

19

Check for leaktightness when engine is running.

 Visual inspection only.

Check values for cylinder head/cylinder head bolts

Number

Designation

Engine 642 in model 907

BE01.30-N-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

205

Max. length (L)

mm

207

For picture, see

AR01.30-D-5800-03TS

 Cylinder head

Number

Designation

Engine 642 in model 907

BA01.30-N-1001-01TSV

Screw/bolt, cylinder head to crankcase

M8

Nm

20

M12

Stage 1

Nm

10

Stage 2

Nm

60

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

 Exhaust manifold

Number

Designation

Engine 642 in model 907

BA14.10-N-1002-02TSV

Stud bolt, exhaust manifold to cylinder head

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09